Eastern Pretech (Malaysia) Sdn. Bhd.

PRESENTATION
ON STRUCTURAL PRECAST IBS COMPONENTS
IN BUILDING INDUSTRIES

15 December 2010
 PRESENTATION CONTENT:

A. INTRODUCTION
 Common Type of Precast Concrete Components
 Technology
 Application and Installation
B. CONSTRUCTION COSTING FOR IBS
 Measurement Works and Built up Cost
 Sample Bill of Quantities
 Comparative Study between Precast and
Conventional Method
 IBS PRODUCTS
-Precast Concrete Product & Unit Bathroom
Precast Hollow Core Slab, Solid Plank, Waffle Slab, Double Tee
Slab, Precast Beam, Precast Column, Precast Facade, Precast
Staircase, Precast Load Bearing Wall, Tunnel segment, Railway
Sleeper (Standard /Metre gauge), Bridge Beam (PRHS, Y, T , M & U
Beams).

Prefabricated Unit Bathroom

Eastern Pretech (Malaysia) Sdn Bhd

 PRODUCT RANGE:
• PRECAST PRESTRESSED PRODUCT STANDARD

HOLLOW CORE SLAB EP HOLLOW CORE SLAB

Width:
1200

Thickness:
150
205
265
325
360
415
460
500

Length:
Customised to
requirement

Eastern Pretech (Malaysia) Sdn Bhd

 PRODUCT RANGE:
• PRECAST PRESTRESSED PRODUCT STANDARD
SOLID PLANKS PRECAST PRESTRESSED
SOLID PLANKS Width:
1200 mm
2400 mm

Thickness:
90 mm
100 mm
125 mm
150 mm
175 mm
200 mm

Length:
Customised to
requirement

Eastern Pretech (Malaysia) Sdn Bhd

 PRODUCT RANGE:
PRODUCT CUSTOMISED SIZE
• PRECAST BEAM RECTANGULAR BEAM Width (B):
300 ~ 1200 at 50 mm increment

Depth (H):
300 ~ 1000 at 50 mm increment

Length (L):
customised

INVERTED TEE BEAM Width (B):

200 ~ 1200 at 50 mm increment

Depth (H):
300 ~ 1000 at 50 mm increment

Length (L):
customised

UPRIGHT TEE BEAM Width (B):

200 ~ 1200 at 50 mm increment

Depth (H):
300 ~ 1000 at 50 mm increment

Length (L):
customised

Eastern Pretech (Malaysia) Sdn Bhd

 PRODUCT RANGE:
• PRECAST COLUMN PRODUCT CUSTOMISED SIZE
BEAM TO COLUMN
CONNECTION
SINGLE TIER COLUMN Width (B):
350 ~ 900 at 50 mm
increment
Corbel
Depth (H):
350 ~ 900 at 50 mm or
increment
BSF
Height (L):
3.0 m ~ 14.0 m at 50 mm
increment

DOUBLE TIER COLUMN Width (B):

350 ~ 900 at 50 mm
increment
Corbel
Depth (H):
350 ~ 900 at 50 mm or
increment
BSF
Height (L):
6.0 m ~ 14.0 m at 50 mm
increment

Eastern Pretech (Malaysia) Sdn Bhd

 PRODUCT RANGE:
• PRECAST STAIRCASES
PRODUCT CUSTOMISED SIZE

Height (L):
Customised to
requirement
PRECAST STAIRCASES
Waist (W):
175 mm

Thread (T):
250 mm

Riser (R):
150 mm
Note:
Nose (N):
Flight and Landings are cast as
25 mm
separate element.
Width (B):
Customised to
requirement

Eastern Pretech (Malaysia) Sdn Bhd

PRECAST WALL/FACADE
PRECAST BRIDGE BEAMS
PRECAST TUNNEL SEGMENTS
PRECAST RAILWAY SLEEPER
USE OF TECHNOLOGY IN PRECAST CONCRETE
CONSTRUCTION
Hollow Core Slabs
- 40% less concrete
- 50% less steel
- 50% less labour
- Better noise reduction
- Better thermal insulation
System Forms
- Beam and column system moulds, battery moulds, etc.
- Enable many casting repetitions with minimal adjustment

Automation
- Concrete batching and delivery
- Slab production
- IT system
- Mechanisation in fabrication

14
FULLY AUTOMATED PRODUCTION FACILITIES
 Application of Precast System for
Different Category of Building
Type of Precast Concrete System :-
Skeletal Frame
Consisting of:

- Structural columns, beams and floor slabs,

with or without lift-walls
- Architectural non-structural façade may sometime be
cladded to the frame.

Suitable for : Commercial buildings, offices, carparks,

hospitals, schools, shopping malls &
factories
…..Application of Precast System for
Different Category of Building
Types of Precast Concrete System :-

Wall Frame
Consisting of: Structural walls and floor slabs

- Suitable for : Residential - High rise flats

- Low to medium rise flats
Private & Government Quarters
Hospital & College Hostels
Hotels & Motels
….Application of Precast System for
Different Category of Building
Type of Precast Concrete System :-

Special System :-

Cell System
Consisting of: a complete walls and slab cast as
a single or multiple box.
Suitable for : Prison cell, etc

Portal Frame
Consisting of: columns and roof rafter beams
Suitable for : Single storey factory building
 Total Precast Construction Method Statement
STEP 1: FOUNDATION PREPARATION
• Preparation of foundation
• Casting of In-situ column stumps / ground
beams with protruding starter bars ready to
receive Precast Columns

Protruding
Starter Bars

Eastern Pretech (Malaysia) Sdn Bhd

 Total Precast Construction Method Statement
3 tiers STEP 1: FOUNDATION PREPARATION
Precast
Column
STEP 2: COLUMN INSTALLATION
• Precast column is slotted into protruding
starterbar
• Column is propped to the required level and
verticality
Protruding
Starter Bars
• Column is grouted with high strength non-
Grouting
Of Starter shrink grout
Bars

Propping
Of Columns

Eastern Pretech (Malaysia) Sdn Bhd

 Total Precast Construction Method Statement
STEP 1: FOUNDATION PREPARATION
STEP 2: COLUMN INSTALLATION
STEP 3: BEAM INSTALLATION
• Precast beam is lifted into position to
Precast be seated onto column corbel
Beam
• Dowel bar is grouted, ready to receive
hollow core slab

Eastern Pretech (Malaysia) Sdn Bhd

 Total Precast Construction Method Statement
STEP 1: FOUNDATION PREPARATION
STEP 2: COLUMN INSTALLATION
STEP 3: BEAM INSTALLATION
STEP 4: HOLLOW CORE SLAB
INSTALLATION
Precast
Column
• Precast Hollow Core Slab is lifted onto
Precast
Hollow
position to be seated onto precast
Core Slab beam

Precast
Beam

Eastern Pretech (Malaysia) Sdn Bhd

 Total Precast Construction Method Statement
STEP 1: FOUNDATION PREPARATION
Beam top STEP 2: COLUMN INSTALLATION
concrete
casting STEP 3: BEAM INSTALLATION
STEP 4: HOLLOW CORE SLAB
INSTALLATION
M&E STEP 5: ASSOCIATED WORKS
services
laying • Beam top rebar is installed
• Beam top concrete casting (C40)

Eastern Pretech (Malaysia) Sdn Bhd

 Total Precast Construction Method Statement
STEP 1: FOUNDATION PREPARATION
Beam top STEP 2: COLUMN INSTALLATION
concrete
casting STEP 3: BEAM INSTALLATION
STEP 4: HOLLOW CORE SLAB
INSTALLATION
M&E STEP 5: ASSOCIATED WORKS (cont..)
services
laying • Shear key joint between hollow core
slab is grouted
• Topping mesh is installed
• Topping rebar is installed
• M&E services installation

Eastern Pretech (Malaysia) Sdn Bhd

 Total Precast Construction Method Statement
STEP 1: FOUNDATION PREPARATION
STEP 2: COLUMN INSTALLATION
STEP 3: BEAM INSTALLATION
STEP 4: HOLLOW CORE SLAB
Topping
INSTALLATION
concrete STEP 5: ASSOCIATED WORKS (Cont..)
• Casting of topping concrete

Topping
rebar/mesh

Eastern Pretech (Malaysia) Sdn Bhd

Total Precast Construction Method Statement
Step 1: FOUNDATION
Step 2: COLUMN
Step 3: BEAM
Step 4: HOLLOW CORE SLAB
Step 5: FLOOR TOPPING
WORKS
Step 6: REPEAT STEP 1-5
FOR SUBSEQUENCE
FLOOR

Eastern Pretech (Malaysia) Sdn Bhd

SECTIONS

1 Precast prestressed Hollow Core Slabs 11 Grouting to beam & column gap
2 Precast beam 12 Precast column
3 Concrete G30 to topping 13 BSF connector
4 Topping rebar ( MB/FB) 14 Grouting to BSF connection gap
5 Fabric reinforcement ( Mesh ) 15 Shearkey grout ( E.mix)
6 Beam top rebar ( support & span ) 16 Grouting to column base
7 Concrete G40 to beam top/infill 17 Grouting to corrugated connection
8 Shearkey rebar 18 Starter bars from pile cap
9 Topping rebar ( EB/PB ) 19 Cast in-situ pile cap
10 Grouting to beam dowel connection
SAMPLE Bills of Quantities-
Precast Supply & Delivery
EASTERN PRETECH (MALAYSIA) SDN BHD
PROPOSED …..
BILL NO. 1
SUPPLY AND DELIVER OF PRECAST COMPONENTS SUPPLY AND DELIVER OF PRECAST COMPONENTS
ITEM DESCRIPTION UNIT QTY RATE AMOUNT ITEM DESCRIPTION UNIT QTY RATE AMOUNT
GRD 1ST 2ND TOTAL (RM) (RM) GRD 1ST 2ND TOTAL (RM) (RM)
5 Precast Column
1 Precast Prestressed Hollow Core Slabs Precast reinforeced concrete (Grade 40) column from
Precast prestressed concrete (Grade 50) Hollow Core Eastern Pretech (Malaysia) Sdn Bhd, design and cast in
Slabs from Eastern Pretech (Malaysia) Sdn Bhd, design approved sizes and including neoprene rubber pad, deliver
and cast in panels size and deliver to site complete with to site complete with lifting loops, all in accordance with
plastic core caps, all in accordance with the manufacturer's the manufacturer's specification
specification (all slabs measured bottom dimension, no
deduction for shearkey area) 5.1 C-X-X : W1 x W2 x H HmmL no 0 -
5.2 C-X-X : W1 x W2 x H HmmL no 0 -
1.1 HCS : EV4-325 mm thick m2 0.00 - 5.3 C-X-X : W1 x W2 x H HmmL no 0 -
1.2 HCS : AV5-265 mm thick m2 0.00 - 5.4 C-X-X : W1 x W2 x H HmmL no 0 -
1.3 HCS : WV6-205 mm thick m2 0.00 - 0 0 0 0 -

2 Precast Prestressed Planks 6 Precast Wall

Precast prestressed concrete (Grade 40/50) planks from Precast reinforced concrete (Grade 40/50) wall from
Eastern Pretech (Malaysia) Sdn Bhd, design and cast in Eastern Pretech (Malaysia) Sdn Bhd, design and cast in
panels size and deliver to site complete, all in accordance panels size and deliver to site complete with lifting loops,
with the manufacturer's specification (all measured bottom all in accordance with the manufacturer's specification
dimension, no deduction for joint area)
xxx mm load bearing wall
2.1 Plank : 110 mm thick m2 0.00 - 6.1 W-X-X : W x L x T mm thick no 0 -
6.2 W-X-X : W x L x T mm thick no 0 -
3 Precast DT Slab 6.3 W-X-X : W x L x T mm thick no 0 -
Precast reinforced concrete (Grade 40/50) DT Slabs from 6.4 W-X-X : W x L x T mm thick no 0 -
Eastern Pretech (Malaysia) Sdn Bhd, design and cast in
approved shape and sizes, deliver to site complete with xxx mm non load bearing wall
lifting loops but excluding, if any, all others inserts and 6.5 W-X-X : W x L x T mm thick no 0 -
M & E items, all in accordance with the manufacturer's 6.6 W-X-X : W x L x T mm thick no 0 -
specification 6.7 W-X-X : W x L x T mm thick no 0 -
6.8 W-X-X : W x L x T mm thick no 0 -
3.1 DT slab : W x L mmL no 0 - 0 0 0 0 -

4 Precast Beams 7 Precast Staircase

Precast prestressed/ reinforced concrete (Grade 40/50) Precast reinforeced concrete (Grade 40) staircase flight and
beam from Eastern Pretech (Malaysia) Sdn Bhd, design landing slab from Eastern Pretech ( Malaysia) Sdn Bhd,
and cast in approved sizes and including neoprene rubber design and cast in approved sizes and deliver to site
strip, deliver to site complete with lifting loops but excluding, complete with lifting loops , all in accordance with the
if any, all others inserts and M& E items, all in accordance manufacturer's specification
with the manufacturer's specification
7.1 S-X-X : W x L x T mm thick no 0 -
4.1 PB-X-X : W x D x L mmL no 0 - 7.2 S-X-X : W x L x T mm thick no 0 -
4.2 PB-X-X : W x D x L mmL no 0 - 7.3 L-X-X : W x L x T mm thick no 0 -
4.3 PB-X-X : W x D x L mmL no 0 - 7.4 L-X-X : W x L x T mm thick no 0 -
4.4 PB-X-X : W x D x L mmL no 0 - 0 0 0 0
4.5 PB-X-X : W x D x L mmL no 0 -
4.6 PB-X-X : W x D x L mmL no 0 - B1/1 TOTAL -
4.7 PB-X-X : W x D x L mmL no 0 -
4.8 PB-X-X : W x D x L mmL no 0 -
4.9 PB-X-X : W x D x L mmL no 0 -
4.10 PB-X-X : W x D x L mmL no 0 -
4.11 PB-X-X : W x D x L mmL no 0 -
4.12 PB-X-X : W x D x L mmL no 0 -
4.13 PB-X-X : W x D x L mmL no 0 -
4.14 PB-X-X : W x D x L mmL no 0 -
4.15 PB-X-X : W x D x L mmL no 0 -
0 0 0 0
SAMPLE Bills of Quantities
- Installation & Grouting Works
SAMPLE Bills of Quantities-
Associated Works
EASTERN PRETECH (MALAYSIA) SDN BHD
PROPOSED…..
BILL NO. 3
ASSOCIATED WORKS ON SITE
ITEM DESCRIPTION UNIT QTY RATE AMOUNT
GRD 1ST 2ND TOTAL (RM) (RM)

1 Vibrated reinforced concrete in :-

1.1 75mm thick slab topping ( Grade 30) m3 0.00 -

1.2 Top & infill of precast beam ( Grade 40) m3 0.00 -

1.3 Infill to beam-column junction ( Grade 40) m3 0.00 -

2 Sawn Formwork to :-

2.1 Edge of precast PB & EB m 0.00 -

2.2 Edge of topping m 0.00 -

2.3 Underside of hollow core slabs at perimeter end m 0.00

3 High tensile and mild steel reinforcement bar

as described in :-

3.1 Beam top ( support & span ) kg 0.00 -

3.2 Slab topping (MB/ FB) kg 0.00 -

3.3 Slab topping (EB/ PB) kg 0.00 -

3.4 Shearkey to Hollow Core Slab kg 0.00 -

3.5 Starter bars from pile cap kg 0.00 -

3.6 DT slab ( bend after installed ) labour only kg 0.00 -

4 BRC steel fabric reinforcement; lapping at joint

; measured nett - allow for laps in rate

In slab topping
4.1 RD6 ( 4.44kg/m2 ) m2 0.00 -

4.2 Power floating to slab topping without hardener

(including floating equipment) m2 0.00

B3/1 TOTAL -
Precast Concrete System Vs Conventional
Cast In-Situ
Description IBS Conventional Cast In-situ (CIS)
1. Time Shorter delivery period leads to early Traditionally take longer and therefore
occupancy. subjected to greater risk of inflationary
escalating cost of construction which may
leads to delayed and abandoned projects
2. Cost In totality:- Direct physical cost may appeared to be
With faster construction time, overall cheaper but in totality:-
cost saving can be achieved. With longer construction period, whereby
Also for the developers or financing and management cost add-on
concessionaires, loan period for will result higher in overall cost.
construction stage is shortened and
rental income generated sooner.
3. Quality Good and consistent quality as precast Inconsistent quality as construction
concrete products is manufactured at a processes are very dependent on manual
controlled factory environment using human labours, site conditions, whether,
modern and mechanized system. quality material on site.
Products are QS tested prior to
delivery.
4. Labour Skilled workers, mainly locals employed Mostly unskilled foreign workers working at
permanently, thus helping our nation the construction under non-conducive
to reduce the dependent on foreign environment which very often results in
labour. poor workmanship, delay and accident.
Also less workers are required as
production processes are mechanized
which give high productivity.
Precast Concrete System Vs Conventional
Cast In-Situ
5. Others a) Longer Building Life span : Better a) Shorter Building life span as lesser
durability as exterior building quality materials control.
facades and main structural frames
are made of concrete with high
quality products.
b) Lower Maintenance Cost : b) Higher Maintenance is required
Building with better and well planned, due to sub-standard or poor workmanship
coupled with more durable and construction
industrialized products.
c) Flexibility and adaptability : c) Less Flexible as columns or
Long span design where building permanent walls are normally spaced
“interior” renovation in the future much closer.
can be accommodated easily.
d) Good Acoustic Insulation :
To achieve a resistance value of Rw= d) Cast in-situ slabs are not a good sound
55 db are possible with Hollow insulation medium.
Core Slabs as flooring components.
This will translates to lesser inter
floor sound transmission will gives
a more quiet indoor environment.
e) Environment Friendly :
Less construction debris / pollution, e) Not so environment friendly, noisy,
quiet construction and minimum dirty, air pollution due to open burning
usage of timber. of timber wasters on site
 COMPARATIVE STUDY -COSTING
- Precast Concrete System Vs Conventional Cast In-situ
SUBJECT : COST COMPARISON BETWEEN IBS SYSTEM VS. CONVENTIONAL CAST INSITU (CIS) METHOD FOR STRUCTURAL FRAME

Amount (RM/m²)
Description IBS Cast Insitu
1. Preliminaries 25 25
2. Structural Frame for Quarter Unit 282 209
3. Brickwalls at Party-wall and all exterior walls Nil 37

4. Common Areas 47 43
5. Site management and rubbish clearing cost 2 5

Total physical construction cost = 356 319

Less : (18) (0)

i)Earlier rental returns @ RM3/m² for 8 months (assumption) (20) (0)
ii)Financial interest saving due to shorter draw-down time in
relation to shorten construction period @ approx. 2% of
contract value.

Therefore, actual cost in total = 318 319

IBS and CIS is about the same cost in total consideration.

Notes to above comparative cost study :
•The cost computed is not an exact costing but a sample meant for the sole purpose of comparison of IBS & CIS method as to show cost in totality.
•The cost for rental returns and financial saving is based on contract model of Build – Lease – Transfer.
•The cost is for structure frame only ( i.e. precast walls/hollow core slabs for IBS system and Cast Insitu (CIS) columns/beams/slabs for conventional
method) excluding works below ground.
However, brickwalls cost for CIS system is needed to do a ‘apple-to-apple’ comparison as the precast system cost has got the party wall and all exterior
wall cost in.
•Architecture and M & E works and all internal infill walls are not included in the above comparative study as the cost of both these items is a constant
value for both systems.
•Factors which is time dependant are based on the construction programme chart Appendix ‘A’.
•The approx. size of one unit of quarter is 110m2 as per the sample drawIng.